Effect of powder mixing process on the microstructure and thermal conductivity of Al/diamond composites fabricated by spark plasma sintering

Two powder mixing processes, mechanical mixing （MM） and mechanical alloying （MA）, were used to prepare mixed Al/diamond powders, which were subsequently consolidated using spark plasma sintering （SPS） to produce bulk Al/diamond composites. The effects of the powder mixing process on the morphologies of the mixed powders, the microstructure and the thermal conductivity of the composites were investigated. The results show that the powder mixing process can significantly affect the microstructure and the thermal conductivity of the composites. Agglomerations of the particles occurred in mixed powders using MM for 30 min, which led to high pore content and weak interfacial bonding in the composites and resulted in low relative density and low thermal conductivity for the composites. Mixed powders of homogeneous distribution of diamond particles could be obtained using MA for 10 min and MM for 2 h. The composite prepared through MA indicated a high relative density but low thermal conductivity due to its defects, such as damaged particles, Fe impurity, and local interfacial debonding, which were mainly introduced in the MA process. In contrast, the composite made by MM for 2 h demonstrated high relative density and an excellent thermal conductivity of 325 W.m^-1.K^-1, owing to its having few defects and strong inter-facial bonding.

Powder Mixing Simulation Using Random Walk Model in Eco-material Preparation

The eco-material composition is not well-distributed in preparation. The eco-material samples were taken for computer image analysis, and its particle numbers and appearance parameters were measured. Based on the mechanism of connective mixing and diffusion, the particles distribution was simulated by a computer using the random walk with Levy flight. The results show that the eco-material microstructure simulated by a computer has an idealized porous structure. The particles distribution has a cluster characteristic that changes with the different size and number of particles in Levy flight trajectory. Each cluster consists of a collection of clusters and shows a structure of self-similar cluster,hence presents a well-defined fractal property. The results obtained from SEM observation are in good agreement with the numerical simulations, and show that the convective mixing presents in the Levy flight walk.

Powder mixed electrochemical discharge process for micro machining of C103 niobium alloy

This work demonstrates the viability of the powder-mixed micro-electrochemical discharge machining(PMECDM) process to fabricate micro-holes on C103 niobium-based alloy for high temperature applications.Three processes are involved simultaneously i.e.spark erosion,chemical etching,and abrasive grinding for removal of material while the classical electrochemical discharge machining process involves double actions i.e.spark erosion,and chemical etching.The powder-mixed electrolyte process resulted in rapid material removal along with a better surface finish as compared to the classical microelectrochemical discharge machining(MECDM).Further,the results are optimized through a multiobjective optimization approach and study of the surface topography of the hole wall surface obtained at optimized parameters.In the selected range of experimental parameters,PMECDM shows a higher material removal rate(MRR) and lower surface roughness(R_(a))(MRR:2.8 mg/min and R_(a) of 0.61 μm) as compared to the MECDM process(MRR:2.01 mg/min and corresponding Raof 1.11 μm).A detailed analysis of the results is presented in this paper.

In-situ powder mixing for laser-based directed energy deposition of functionally graded materials

The mixing of powders is a highly relevant field under additive manufacturing,however,it has attracted limited interest to date.The in-situ mixing of various powders remains a significant challenge.This paper proposes a new method utilizing a static mixer for the in-situ mixing of multiple powders through the laser-based directed energy deposition(DED)of functionally graded materials.Firstly,a powder-mixing experimental platform was established;WC and 316L powders were selected for the mixing experiments.Secondly,scanning electron microscopy,energy dispersive spectroscopy,and image processing were used to visually evaluate the homogeneity and proportion of the in-situ mixed powder.Furthermore,powder-mixing simulations were conducted to determine the powder-mixing mechanism.In the simulations,a powder carrier gas flow field and particle mixing were employed.Finally,a WC/316L metal matrix composite sample was produced using laser-based DED to verify the application potential of the static mixer.It was found that the static mixer could adjust the powder ratio online,and a response time of 1–2 s should be considered when adjusting the ratio of the mixed powder.A feasible approach for in-situ powder mixing for laser-based DED was demonstrated and investigated,creating the basis for functionally graded materials.

EXPERIMENTAL RESEARCH ON CrAl MIXED POWDERS BY MECHANICAL ALLOYING

Thechangesof microstructure, phase? structureand microhardnessof Cr Al mixed powders in the processof mechanical? alloying ( MA) have? beeninvestigated by X ray diffractionanalysis , SEM examination and microstructure testing. The results show that the mi crostructure of Cr Al mixed powderssubjected? to mechanicalalloying for96 hoursexhibits super saturated solid solution of Cr andintermetalliccompound η AlCr2 .

Application Research on Powder Mixed EDM in Rough Machining

Powder Mixed Electric Discharge Machining (PMEDM) has different mechanism from conventional EDM, which can improve the surface roughness and surface quality distinctly and to obtain nearly mirror surface effects. It is a useful finish machining method and is researched and applied by many countries. However there are little research on rough machining of PMEDM. Experiments show that PMEDM machining makes discharge breakdown easier, enlarges the discharge gaps and widens discharge passage, and at last forms even distributed and "large and shadow" shaped etched cavities. Because of much loss of discharge energy in the discharge gaps and reduction of ejecting force on the melted material, the machining efficiency gets lower and the surface roughness gets small in PMEDM machining in comparison with conventional EDM machining. This paper performs experimental research on the machining efficiency and surface roughness of PMEDM in rough machining. The machining efficiency of PMEDM can be highly increased by selecting proper discharge parameters (increasing peak current, reducing pulse width) with approximate surface roughness in comparison with conventional EDM machining. Although PMEDM can improve machining efficiency in rough efficiency, but a series of problems like electrode wear, efficiently separation of machined scraps from the powder mixed working fluid, should be solved before PMEDM machining is really applied in rough machining. Experiments result shows that powder mixed EDM machining can obviously improve machining efficiency at the same surface roughness by selecting proper discharging parameters, and can provide reference accordingly for the application of PMEDM machining technology in rough machining.

Study on the Evaporation Kinetics of Zinc and Lead in Zn-Pb-Bearing Dust Pellets Mixed with Coal Powder

The study on the evaporation kinetics of zinc and lead in the pellets made of ZnPbbearing dust mixed with carbon ,in nitrogen atmosphere at the temperature range between 1 100 and 1 300 , shows that the reduction temperature has a significant effect on the evaporation rates of zinc and lead and that both the particle size of coal powder and the extra carbon content have no effect on the evaporation rates . The obtained activation energies for the evaporation of zinc and lead are 7942 kJ/mol and 8874kJ/mol respectively. The evaporation rate of zinc is controlled by the reaction between zinc oxide and CO while that of lead is controlled by lead volatilization and the diffusion of gaseous lead through gas boundary layer covering the surface of liquid lead.

Effect of Recycled Mixed Powder on the Mechanical Properties and Microstructure of Concrete

In this paper,recycled bricks and recycled concrete were applied to prepare eco-friendly recycled mixed powder(RMP)cementitious material,as a supplementary to replace conventional cement for improve the recycling of construction and demolition waste.Based on the effect of cementitious materials on the hydration of silicate cement,the effects of RMP on the workability,mechanical properties and microstructure of recycled mixed powder concrete(RMPC)with the different replacement ratios and the 8:4 and 6:4 mixing ratio of recycled brick powder(RBP)and recycled concrete powder(RCP)were investigated.The results showed that the fluidity of the mix decreased with increasing of the replacement ratio and the mixing ratio of RBP and RCP,but the influence of the fluidity was smaller within 15%replacement ratio.As the replacement ratio increases,the internal pore structure of RMPC tends to be loose and porous,which exhibits a significant pore volume distribution characteristic.The number of large capillaries was considerably increased at replacement ratio of 45%.The 7 d compressive strength of RMPC was slightly lower than that of ordinary concrete.The compressive and splitting tensile strengths of RMPC at 28 d increased by 4.2%and 10.1%,respectively,with increasing curing age at 15%replacement ratio and 6:4 mixing ratio.The RMPC mechanical strengths with RBP and RCP at the mixing ratio of 6:4 was higher than those of 8:2.Finally,a basis for the recycling of RBP and RCP in the construction industry can be provided by the results of this study.

Effect of processing parameters on the microstructure and thermal conductivity of diamond/Ag composites fabricated by spark plasma sintering

Diamond/metal composites with 50 vol.% diamond have been produced by spark plasma sintering（SPS） using pure Ag as a matrix and diamond particles as reinforcement.Three kinds of powder mixing processes were used to prepare the mixture of diamond/Ag powders：dry mixing without milling medium,wet mixing and magnetic blending.Subsequently,they were all consolidated by SPS at various processing parameters to produce bulk diamond/Ag composites.Then samples were heat treated in order to obtain a higher thermal conductivity.The effect of processing parameters on the morphologies of the mixed powders,the microstructure and the thermal conductivity of the composites were investigated by comparing the experimental data.It reveals that particles were easy to agglomerate and the distribution of mixed powders was inhomogeneous by dry mixing method,and wet mixing method is too complex.The most favorable mixing process is magnetic blending by which the powders can be homogenously mixed and the composites prepared by optimized SPS processing parameters can obtain the highest relative density and the best thermal conductivity among the composites prepared by different processes.The magnetic blending diamond/Ag composites even have a 23% increase in thermal conductivity compared with pure silver sintered by SPS.

Dielectric properties of spark plasma sintering AlN-W composite ceramics

In order to develop AlN composites suitable for high average power electronic tube, AlN-W materials were prepared by spark plasma sintering. The effects of manufacture parameters on dielectric loss tangent and permittivity constant were investigated, which include powder-mixed method, milling time of high-energy ball milling, starting powder particle size, sintering temperature and holding time and adding amount of the conductive second phase. The results showed that A1N-W materials sintered at the temperature of 1700℃ holding for 5 min with 10 vol.% W showed the best dielectric loss tangent larger than 0.81 at the frequency 1 kHz-1 MHz. In addition, magnetic stirring mixed powder and lower sintering temperature led to the better propelties because of the higher porosity. The samples sintered from the starting AlN powder with smaller particle size also had the better properties.

Mixing of particles and powders:Where next?

Industrial mixers for powders and granular materials operate with no effective control of mixture quality and lack scientific design. The last twenty years have seen growth in understanding of mixing and mixers. However, research falls far short of what is needed for on-line characterisation of mixture quality. Secondly, although theoretical descriptions of a few mixer types have been reported, these fall far short of what is needed for equipment design. Two thrusts could revolutionise this situation. One is a scientific characterisation of mixer structure applicable to industrial scale as well as laboratory scale equipment; this is now within our grasp using digital imaging. The other is the development of ideas to overcome the restricted number of particles that can be used in the Distinct Element Method （DEM） for mixers. The goal should be to take the designer through a sequence of steps to the most appropriate mixer size, configuration and operating conditions for a given process duty.

DEM analysis of the effect of electrostatic interaction on particle mixing for carrier-based dry powder inhaler formulations

Particle interactions play a significant role in controlling the performance of dry powder inhalers （DPIs）, which mainly arise through van der Waals potentials, electrostatic interactions, and capillary forces. Our aim is to investigate the influence of electrostatic charge on the performance of DPIs as a basis for improv- ing the formulation of the particle ingredients. The mixing process of carrier and active pharmaceutical ingredient （API） particles in a vibrating container is investigated using a discrete element method （DEM）. The number of APl particles attaching to the carrier particle （i.e., contact number） increases with increas- ing charge and decreases with increasing container size. The contact number decreases with increasing vibrational velocity amplitude and frequency. Moreover, a mechanism governed by the electrostatic force is proposed for the mixing process. This mechanism is different from that previously proposed for the mixing process governed by van der Waals forces, indicating that long-range and short-range adhesive forces can result in different mixing behaviours.

Influence of dysprosium substitution on magnetic and mechanical properties of high intrinsic coercivity Nd-Fe-B magnets prepared by double-alloy powder mixed method

The double-alloy powder mixed method is very proper for developing new small-mass products by changing the composi- tion of sintered Nd-Fe-B magnets, and there is little research on this aspect. The variation on magnetic and mechanical properties of high intrinsic coercivity Nd-Fe-B magnets prepared by double-alloy powder mixed method was discussed, which is a method blend- ing two-type main phase alloy powders with different components. The results showed that the intrinsic coercivity and density of sin- tered Nd-Fe-B magnets increased gradually with the increase in Dy content, and the double-alloy powder mixed method could obtain high intrinsic coercivity Nd-Fe-B magnets with good crystallographic alignment and microstructure. The bending strength of sintered Nd-Fe-B magnets declined, and the Rockwell hardness of sintered Nd-Fe-B magnets first declined, and then increased with the in- crease in Dy content. The microstructure showed that there existed the phenomenon that the Dy element diffused into main phase dur- ing sintering process, and the distribution of Dy content in main phase had some variation in homogeneity as a result of incomplete reaction between the double-alloy powder types.

Microstructure evolution and mechanical behavior of Ni-based single crystal superalloy joint brazed with mixed powder at elevated temperature

Brazing of a Ni-based single crystal superalloy has been investigated with the additive Ni-based superalloy and filler Ni–Cr–W–B alloy at 1260℃, and attentions were paid to the microstructure evolution during brazing and the stress-rupture behavior at 980℃ of such brazed joints after homogenization. Microstructure in the brazed joint generally includes brazing alloy zone（BAZ）, isothermally solidified zone（ISZ） and diffusion affected zone（DAZ）. Microstructure evolution during this brazing process is discussed at the heating stage, the holding stage and the cooling stage respectively, according to the diffusion path of B atoms. Initially well-distributed γ’/γ’ microstructure in the homogenized bonded zone after heat treatment and substantial γ’ rafts enhance the post-brazed joint to obtain a stress-rupture lifetime of more than 120 h at 980℃/250 MPa. On the other hand, the decreased stress-rupture behavior of post-brazed joint, compared with parenting material, is ascribed to the presence of inside brazing porosity and stray grain boundary, which not only reduces the effective loading-carrying area but also offers preferential sites for creep vacancy aggregation to further soften stray grain boundary. And finally an early fracture of these post-brazed joints through the intergranular microholes aggregation and growth mode under this testing condition was observed.

Characterization of nanoparticle mixed 316L powder for additive manufacturing

Nanoparticles reinforced steels have many advantaged mechanical properties.Additive manufacturing offers a new method for fabricating nanoparticles reinforced high performance metal components.In this work,we report the application of low energy ball milling in mixing nanoparticles and micron 316 L powder.With this method,0.3 and 1.0 wt% Y2 O3 nanoparticles can be uniformly distributed on the surface of 316 L powder with the parameters of ball-to-powder ratio at 1:1,speed at 90 rpm and 7 h of mixing.The matrix 316 L powders remain spherical in shape after the mixing process.In the meantime,the effect of low energy ball milling and the addition of Y2 O3 nanoparticles on the powder characteristics(flowability,apparent density and tap density) are also studied.Results show that the process of low energy ball milling itself can slightly decrease the flowability and apparent density of the 316 L powder.The addition of 0.3 and 1.0 wt% Y2 O3 nanoparticles can also decrease the flowability,the tap density and the apparent density compared with the original 316 L powder.All of these changes result from the rough surface of the mixed powder produced by ball milling and the addition of Y2 O3 nanoparticles.The powder’s rough surface can increase the coefficient of friction of powders.The mixture of 316 L powder and Y2 O3 nanoparticles can be successfully used for selective laser melting(SLM).The relative density of SLM 316 L-Y2 O3 is measured at 99.5%.However,Y2 O3 agglomerations were observed which is due to the poor wettability between 316 L and Y2 O3.

A Comparative Study on the Microstructure and Properties of ITO Targets and Thin Films Prepared from Two Different Powders

With the rapid development of indium tin oxide(ITO)in the electronic display industry,choosing which raw powders to prepare high-quality ITO targets has always been a controversial topic.In the work,in order to clearly understand the effect of the raw powders on the microstructure and properties of ITO targets and thin films,tin-doped indium oxide(dITO)and In_(2)O_3-SnO_(2)mixed(mITO)powders were chosen to prepare ITO targets for depositing the films and a comparative study on their microstructure and properties was conducted.It is found that,(1)dITO targets possess a higher solid solubility of tin in indium oxide and more uniform elemental distribution,while there are a higher density,a finer grain size and a higher mass ratio of In_(2)O_3 to SnO_(2)for the mITO targets;(2)dITO films with more coarser columnar grains and a rougher surface prefer to grow along the[100]direction in an Ar atmosphere;(3)the conductive property of ITO films only depends on the doping amount of tin and is independent of the raw powders and the preparation process of the target source;(4)dITO films possess the superior optical property and narrower optical band gap;(5)the etching property of mITO films is superior to that of dITO films due to the lower solid solubility of tin in indium oxide.

Numerical analysis of enhanced mixing in a Gallay tote blender

The mixing performance of a multi-bladed baffle inserted into a traditional Gallay tote blender is explored by graphic processing unit-based discrete element method software. The mixing patterns and rates are investigated for a binary mixture, represented by two different colors, under several loading profiles. The baffle effectively enhances the convective mixing both in the axial and radial directions, because of the disturbance it causes to the initial flowing layer and solid-body zone, compared with a blender without a baffle. The axial mixing rate is affected by the gap between the baffle and the wall on the left and right sides, and an optimal blade length corresponds to the maximum mixing rate. However, the radial mixing rate increases with the blade length almost monotonically.

FE SIMULATION AND EXPERIMENTAL VALIDATION OF POWDER MIXED EDM PROCESS FOR ESTIMATING THE TEMPERATURE DISTRIBUTION AND VOLUME REMOVED IN SINGLE CRATER

This study reports the results of a finite element simulation of powder mixed electric discharge machining process for H11 Hot Die steel material using relevant boundary conditions and reasonable assumptions.The crater shape was developed using simulated temperature profiles to estimate the volume removed in a single crater.The temperature distribution on the workpiece was used to predict the cooling rate and calculate the stresses generated due to thermal loading.Subsequently,the simulation results were experimentally validated by physically measuring the crater shape and volume.From the results it was concluded that about 25%of heat is transmitted to the workpiece during machining at the process conditions used in the experiment.The microscopic pictures showed bigger craters with increase in current.The machined surface showed overlapping craters with surface cracks suggesting a high cooling rate.

Finite element modeling and analysis of powder mixed electric discharge machining process for temperature distribution and volume removal considering multiple craters

Powder mixed electric discharge machining(PMEDM)is one of the modern developments in electric discharge machining(EDM)process.In the present work,finite element modeling has been carried out considering randomly oriented multiple sparks during PMEDM.Transient thermal analysis is done to obtain temperature distribution,volume removal,and proportion of volume removed by melting and evaporation at different current,pulse on time and fraction of heat that enters to work piece.Gradually growing spark behavior and Gaussian distribution of heat source is used to simulate multiple craters.Temperature distribution along radial direction shows peak temperature at center of spark and thereafter a gradual decrease with increase in radial distance.Along depth direction temperature sharply decreases that forms wider craters with shallow depth in PMEDM.Peak temperature and volume removal increases with current more rapidly.Volume removal by melting is much higher than evaporation at lower current settings and with higher current almost equal amount of material is removed by melting and evaporation thus reducing the re-solidification of melted material.Current plays a significant role behind the contribution of material removal by evaporation followed by fraction of heat.Increase in pulse on duration increases the total volume of material removal however does not significantly increase the proportion of volume removal by vaporization.

Microstructures and Properties of NiCrBSi/WC Biomimetic Coatings Prepared by Plasma Spray Welding

The NiCrBSi/WC biomimetic coatings were prepared on the low carbon steel substrate by plasma spray welding with mixed powders （WC-Col2＋NiCrBSi） based on the bionic principles, and the coating characteristics were investigated. The results indicate that the coatings have a full metallurgical bond in coating/substrate interface, and consist mainly ofy-Ni, WC, Cr23C6, Cr7C3, Ni3Si, CrsB3, and FeNi3 phases. The powder composition influences the microstructures and properties of the coatings. The WC content and the hardness of coatings increase with the mass fraction of WC-Co 12 powder. The biomimetic coatings have much higher wear resistance compared with the low carbon steel, which is attributed to the combination of hard WC and chromium carbide particles （bionic units） and soft y-Ni matrix in the coatings. It is favorable to prepare the biomimetic coating by plasma spray welding with the mixed powders （20wt%WC-Col2＋80wt%NiCrBSi） for improving the wear resis- tance of the coating.